CHAPTER-21

ROLE OF ELECTRICAL AND MECHANICAL ENGINEERS

(AN OVERVIEW)
Activities of ONGC are highly capital intensive. A large chunk of capital is invested in
the equipment worth more than Rs.20,000 crores which are used for exploration &
exploitation of hydrocarbons. Maintaining such vast asset of equipment is a gigantic task
in itself. Mechanical & Electrical engineers in ONGC have a prime role in the upkeep of
equipment. Though Mechanical & Electrical engineers by their basic qualification are
being recruited in Production, Drilling, Material Management, Logistics & other stream
as well but persons designated as AEE(Mech) and AEE(Elect) are assigned the
maintenance functions and other associated tasks.
Over the years a considerable expertise has been acquired by maintenance engineers
in upkeep of vast variety of equipment viz. Drilling Rig equipment, Production
Installation equipment, large process plant equipment of Hazira & Uran Plant, Gas
Turbines etc.
It is equally important to keep pace with rapid technological advancement and adapt &
absorb the new technologies for the smooth functioning of operations at optimum cost.
Hence Technology Management plays an important role in the activities of ONGC & the
responsibility is aptly shouldered by in-house engineers.
Before we start discussing roles of engineers of various disciplines
in
ONGC, it is imperative to discuss the Macro relationship between these disciplines
or activities.
In fact ONGC or for that matter any industry can equated with human body .A human
being has a purpose for which, its all parts of body work in tandem to deliver an optimal
output. Similarly, an organisation also has a purpose for which
different
disciplines would work in tandem to achieve me objectives.
In a human body, i s unwise to state that any one organ is
dispensable without affecting the output of human being. Similarly
itshall not be prudent to emphasise the role of any one discipline
in the organization.It is the collective effort of all the employees
/departments which results in an efficiently run organization.
Further in a body some organs have a mutual synergy, likewise
there is a synergy between the maintenance disciplines. The
interdependence and the common working of Mechanical and
Electrical disciplines is worth mentioning. Hence the two
disciplines are being treated in a special consolidated way.

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The common roles of the: two disciplines have been dealt in Section
A. However in Section B, we would dwelve upon the special roles
played by the engineers of the two disciplines.
Section A "Common Role"
As per the New CRC structure, the career growth matrix of Electrical/ Mechanical
Engineers is designed as follows,
CAT-I : Operation & Maintenance of Equipment in Drilling rigs (Onshore/
Offshore)
CAT-II : Operation and Maintenance of Equipment in Production installation
onshore/offshore & Process plants
CAT-III: Operation & Maintenance of Equipment in workover Rigs onshore/
offshore/ MR.
CAT -IV: Electrical: Central workshops/Asset workshops/ E&C/ Contract Cell/
Building Construction, Maintenance of Building & Colony
Mechanical: Central workshops/Asset workshops/ E&C/ Contract Cell
CAT-V : Management services/ QAD / INDEG/ SHE / EM/ TA /
Provisioning/Energy Cell/Institutes etc.
Of the above categories, either of CAT-I or CAT-II is compulsory.
An Electrical/Mechanical Engineer is required to opt and complete at least three
categories of these job rotations in three regions including northeast. The time duration
in each category should be a minimum of two years. Promotion to corporate level prerequisites that an individual should have completed three regions and three categories
of job or is in third region and/ or third job category when considered for promotion.
CRC Set up and role of Mechanical/ Electrical Engineer
Under.CRC, there are mainly 3 groups under which these Engineers function: A.
B.
C.

Engineering Services
EM/TA/QA
Miscellaneous

A.)
ENGINEERING SERVICES
The Engineering group is headed by Chief Engineering Services centrally and by Head
Engineering Services at Assets and plants level. The main sub functions of
Engineering Services are as follows,
1. Design
2. Works
3. Maintenance

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A-1.) Design Group; This group is responsible for the preparation of plans & designs
for
project/ work to be under taken at Onshore or Offshore. There are basically two sub
groups; they are "onshore design group" and "offshore design group".Onshore
group takes care of the design part of project/ works under taken in Onshore Assets.
Offshore group takes care of the design part of projects/ works undertaken in offshore
platforms/ wellhead platforms etc.:
A-2.) Works Group: This group is headed by "Head (Works)" centrally & by
"Location Manager (Works)" at assets. For offshore group at Mumbai, there is a
common head of works for all three Assets. The group is responsible in executing the
projects/ works finalized by the Design group. The job includes preparation of
estimates, finalization of tenders, Bid Evaluation Criteria (BEC), inviting and
evaluating tenders, award and execution of the job.
A-3) Maintenance Group:
The Maintenance Group functions can be broadly classified in two subgroups.
Planning & Major Maintenance:
This group is generally headed by a Location manager, i.e. LM (Maintenance)at
Assets under onshore group & a common head of maintenance for all three Assets of
offshore group. The group is responsible for the technical support & major
maintenance of Equipments in Drilling services (DS), Technical Services, Operation
Services (ST), work over services (WS) &. W/Shops.
Operational Maintenance at site:
This constitutes the engineers posted at the Drilling Rigs & Workover Rigs, Production
installations & Process Plants who are directly responsible for day to day upkeep and
operation of the equipments installed at these sites.
In Maintenance Group, the role of Mechanical and Electrical engineering is from
the procurement to the disposal of the equipment after, it has lived its life. The
different roles can be summed up as below:

Selection &. Acquisition of Equipment

Maintenance
Repair and Fabrication
Disposal of Equipment,

These are discussed in following sections

Selection

& Acquisition of Equipment

Once the equipment is acquired it is used for a long period of time, ten years or
possibly even 20 years. While in use, equipment controls the quantity and quality of
the output (in form of drilling meterage or crude oil/gas production). The selection of

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equipment also influences future operation and maintenance costs, thus making: it
important to consider both the acquisition cost and sustaining cost when making the
selection.
Thus in ONGC where equipment of various kinds worth more than Rs.20,000 crores
are in use. the importance of Mechanical/Electrical departments can be visualized.
Especially in view of the ever increasing requirement of higher productivity, cost
reduction, pollution free environment etc. owing to the globalization of economy and
increasing competition. In this competition "Survival of the Fittest" the phrase often
used, has a meaningful place in the present scenario.

Maintenance of equipment

The Mechanical/Electrical disciplines plays a vital role in maintaining equipment in

use in Exploration, Drilling & Production of Oil & Gas. Dedicated team of Mechanical/
Electrical Engineers are working in Assets and Basins for maintaining the equipment
of Exploration, Drilling, Production sites They are responsible for repairing these
equipment in the Assets or Central Workshop under its control.
Maintenance is a combination of many actions carried out to retain an equipment in or
to restore it to an acceptable condition.
The objectives of maintenance are:
a) To increase equipment availability.
b) To ensure operational readiness of equipment at all times.
c) To ensure safety of personnel using these equipment.
d) To reduce maintenance costs, delays and shutdowns.
e) To extend the useful working life of the equipment.
The types of Maintenance are:

Break Down Maintenance: Repair

to restore equipment failure

Preventive

Maintenance Or Scheduled Maintenance (Inspection, Lubrication,

minor repairs, adjustments etc.) Inspection servicing, time based major overhaul)

Predictive

Maintenance or Condition Based Maintenance:

(Continuous monitoring of critical component where prior indication of
impending fault is received)
Condition Based Maintenance requires monitoring of some condition indicating
parameters of the units. Condition Monitoring can be defined as monitoring the health
of equipment and its accessories through an external methodology without
necessitating either decommissioning or dismantling of the equipment itself. Once the
area of deficiency, if any, has been identified through this methodology, a planned
system can be followed for repairs/replacement after ensuring availability of all the
necessary inputs, with minimum operational disruption.
If the consequences of failures are sufficiently high or where safety of
personnel is a relevant factor, it is worth-while to adopt condition monitoring.
LIMITATION:
1. Some of the causes of plant failure can't be detected in advance.
2. Costly in Manpower and monitoring instrument.
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CONDITION MONITORING TECHNIQUES:

1 ON Load Techniques: Visual, Temp., pressure, Lub Oil Monitoring, Corrosion
monitoring; Infra Red thermography.
2. Off Load Technique: Radiography, Ultra Sonic inspection, boroscope
inspection.
3.On/Off Load Technique:
Leak Detection, Crack Detection, Vibration
Monitoring.
The Mechanical and Electrical sections of ONGC have been able to meet the
Maintenance objectives successfully. The; targets of equipment availability of over 98%
for Drilling Rigs and Work over Rigs and system availability of 100% for Production
installations is being maintained for years together which in turn has enabled the
organization to accomplish its targets of metreage and crude oil production.
As the type of equipment handled by the mechanical/Electrical Engineers are
quite different, the specific role and the brief of equipment handled by them
has been dealt in Section-B separately.
Repair and Fabrication at Central Workshops/Asset workshops:
All the maintenance and repair jobs cannot be carried out at rig site or
installations or platforms. Many of the major jobs require special tools and jigs etc,
which are available at central workshops and Asset workshops. ONGC has two major
central workshops, one at Baroda and the other at Sibsagar. Every Asset has its
own workshop to cater the minor level of repair to meet requirements of the
Asset.
1. Central workshop: Major overhauling, fabrications and machining jobs are
carried out in these workshops. The equipment like big Diesel Engines, mud
pumps^rig equipment like crown block, drawworks, swivel etc. HT & LT
Motors, Alternators and Transformers are overhauled, repaired and serviced
here. The jobs are generally planned and scheduled in nature.
2. Asset workshop: Minor jobs, bearing changes, rewinding of LT motors,
generators and self-starters. Servicing of transformers and batten1 chargers are
taken up here. Emergency repairs are also under taken in respect of critical
motors or equipment.
The repairs of equipment and fabrication of structures, pressure vessels tanks etc.
are
carried out by mechanical engineers in the Project and Central
Workshops. For capital repairs the equipment is completely dismantled, stripped,
cleaned and then inspected. After inspection, the decision to replace the worn
out parts is taken and then equipment is assembled and test run to full satisfaction
of the user department. This procedure ensures trouble free run of the equipment
for its life period. This way the objective of extending the useful life of the
equipment is
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ensured. The operation and repair of the equipment requires spares parts
management where mechanical engineering section plays a vital role. Planning,
indenting, procuring of right kind of spares, from right source, of right quality, at right
price and at right time is necessary for maintaining high equipment a lability. In
this INDEG (Import Substitution Group) consisting of mainly Mechanical engineers has
played a vital role by import substituting number of fast consumable spares" for imported
equipment.
Disposal of Equipment
Each equipment has a prescribed life after which the high repairing and running cost
renders it useless or uneconomical. Before declaring it condemned and disposing it
off, the team of operation man along with maintenance personnel examines. and
declares the equipment B.E.R. i.e. beyond economical repair. Thereafter the
equipment is disposed off.
To meet the challenge in this competitive world, ONGC has to adopt the policy of 'Zero
Defect'. The repair and maintenance philosophy is to be such that equipment perform
as good as new all the time without any degradation. For this ONGC has to gear-up,
train the personnel in the latest technology and repeatedly hammer into the minds of
maintenance personnel that failure can be reduced to Zero.
B.) EM (Equipment
Assurance)

Management)/

TA

(TechnicalAudit)/OA

(Quality

Equipment Management:
The major, functions of Equipment Management department are:
1.
2.
3.
4.
5.

Preparation of Maintenance practices and codes

Preparation of policies and procedures.
Energy Audit & Monitoring
Indigenisation of parts & Equipment and Vendor Development.
Freezing of Equipment Specifications & Standardization of Equipment.

The group closely monitors the performance of equipment, do case studies & analysis
of equipment failures etc. The group formulates various maintenance procedures
and techniques that help in improving the equipment availability, reliability and also
improving the productivity. EM also formulates policies for condemnation of equipment/
rigs etc.
The Energy Department of EM monitors the Energy consumption of Equipment/
Installation/ Rigs and compares with stipulated Energy indexes. Energy Auditing
of various installations helps in reducing energy consumption, also generates
awareness of energy conservation amongst the employees of ONGC.
The INDEG or Indigenisation cell of EM tries to indigenise the otherwise imported
components or equipment to save precious foreign exchange. The department
designs.

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arranges testing and develop replacements. Vendor development is an important

function of this group.
Standardization Group is another arm of EM. This group standardizes the
specifications of various equipment and material so that as far as possible similar item
or equipment is purchased at all work centres.
Technical Audit: The major functions of Technical audit group are,
1. Technical Audit of Equipment in Drilling Services.
2. Technical Audit of Equipment in Installations/ Plants, or Platforms.
3. Condition Monitoring
This department undertakes detailed study of equipment in use and analyzes their
usage, equipment availability; consumption records and critically evaluates the
requirements of system, usage of equipment. These studies help in fine-tuning the
operation & maintenance practices and also ensure optimal usage of equipment
and reduce idle existence. Condition Monitoring is another important function, which
is carried out on continuous basis at all work centres. Condition monitoring helps in
identifying possible failures well in advance so that a possible corrective measure
could be worked out and applied to prevent any major damage or shutdown. Condition
monitoring also helps in increasing the equipment availability and in modification of
equipment and or its systems to prevent recurring faults or problems.
Quality Assurance (QA): This group is bestowed with the responsibility of ensuring
the purchase of products as per specifications and as per stipulated standards. All
purchases done by ONGC require clearance from QA Department before accepting the
same by the stores or indenter. QA dept often take the help of established testing
centers/ universities and laboratories to undertake tests of material and products.
C) MISCELLANEOUS:
1. Management groups; Often a Mechanical/Electrical Engineer may have to
under
take jobs outside the mainstream of Mechanical/Electrical Engineering. Viz. EA
(Executive assistant to Asset Managers/ Corporate Chiefs/ Directors). Working as EA
or in groups like MIS (Management information system), an executive is expected to
function as a laisoning officer. He has to, collect data from various groups/
assets/
Basins etc and analyze the same for helping management in decision-making.
2. Safety Health & Environment (SHE): This is an important function in ONGC. This
group plays the role of monitoring & implementation of rules and regulations in the
field of safety and environment protection. Their function is to ensure the safe
working of equipment, safety of men and material. The group also liaison with
various outside governmental agencies in safety audits and compliance
of stipulations. IPSHEM-GOA is a institute that trains and research in safety aspects.
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3. Building Maintenance (Construction-Electrical Maintenance of Building

&Colony): Up keeping of office buildings and residential colonies, electrification,
central air conditioners, lifts, UPS, lightings, conference room equipment etc. are also
part of the job. Routine maintenance, repairs and modifications are also to be carried
out. In case of new construction it involves Contract Management also.
4. Contract , cell( For Electrical Works): The contract cell prepares estimates of work
or repair job based on SOR(Schedule of rates) or RA(Rate analysis) or on Market
rates. The cell also prepares detailed drawings and tender documents; They float
v
tenders, evaluate the bids, award the job and get the job executed.
5. Institutes: ONGC has various research and training Institutes. The Institutes are
IEOT, IOGPT, IMD, RTIs, IPSHEM, GEOPIC, KDIMPE, IDT, IRS, STIs etc:
A
Mechanical/Electrical Engineer may be posted in these institutes as a faculty or even for
research.
SECTION B
Specific Role of ELECTICAL ENGINEER:
I) Operation & Maintenance of equipment in drilling rigs: Drilling rigs are used for
the drilling of exploratory as well as development wells. Drilling rigs are of two types:1. Mechanical Rigs
2. Electrical Rigs
.
i
Presently on most of the locations, ONGC is using Electrical rigs. Electrical Rigs are
further subdivided into two types: 1. DC-DC Rigs: hi these rigs, power for Draw-works and mud-pumps is generated
in DC itself.
2. AC-SCR Rigs: Most commonly used drilling rig. The total power required by the
drilling rig is generated by AC Alternators. This AC power is rectified into DC
power for DC motors (Draw-works & Rotary table (in case of independent Rotary
drive) & mud-pumps), using Silicon Controlled Rectifier (SCR) bridges.
A drilling rig has following electrical equipment for various operations of drilling.
1.

DG. sets:
These are generally Diesel engine driven AC alternators of various
capacities depending upon the type of rig. On AC-SCR rigs, generally 600 Volts,
50/
60 Hz, 1250/ 1430 KVA AC alternators are used. The power generated by these
alternators is fed to a common 600-volt bus bar. For connecting all the alternators
on the same busbar, synchronizing system is installed along with
various
protections and control circuits for these alternators. The Alternators used are mostly
brushless type in order to reduce maintenance & hence more reliability.

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2. AC motors & controls: AC Motors are used for various utilities viz. Mud
agitators, superchargers, desander, desilter, degassers, shale shakers, oil pumps,
fans, fuel transfer pumps etc. These motors are generally 3 phase induction
motors controlled by DOL starters/ star delta starters/ autotransformer starters/
soft starters etc. All the motors can be started/ stopped by a remote switches,
installed near the motor or a location convenient to driller/ chemist etc. Motors
installed in hazardous areas are with flame Proof characteristics.
3. DC motors and controls: DC motors are one of the major drive horses of a rig.
These high capacity motors are used to drive the draw-works, rotary table and
mud-pumps. These are 750 Volts, separately excited, 900/ 950/ 1000 HP motors.
Separately excited motors are used for their high starting torque characteristics.
4. SCR Packs: Generally three or four SCR packs are installed in an ACSCR rig.
One SCR pack can be assigned to one equipment i.e. either a mud-pump or a
draw-works. Each SCR pack contains one SCR (Thyrister) Bridge, its firing
circuit, various controls and protections. The AC power generated by 600 Volt
alternators is rectified to DC with the help of these SCR packs. Various selection
schemes to assign motors to various SCR packs helps in increasing the reliability
and availability of these SCR packs/ DC motors and equipment.
5. Transformers: Each rig has two transformers to step down the generated voltage
of 600-volts to 415 volts (or 220-volts for American rigs), the voltage required by
the three-phase induction motors. These transformers are generally air-cooled type.
6. Lighting Transformers: Lighting transformers are used to step down 415-volts
to the lighting voltage of 110-volts per phase. All the lightings used on the rig are
rated at 110 volts. This is to reduce the operating voltage and thus reducing the
risk of Electric shock.
7. Air conditioners and lighting systems: Air conditioners are used to control the
temperatures in controller cabins (ACPCR & DCPCR) and also of crew rest
rooms. Lights are provided in the work areas and in peripheries. The lighting
system is of 2 types; Flame proof and non-flameproof Flameproof lightings are
used In places where there is a likely hood of encountering inflammable gases or
oil.
8. pport, provisioning etc.:
Providing base support for the men &
equipment at site is, also a very important function. These include Field
maintenance parties and procurement cells. The Field Maintenance Parties
attends various emergency shutdowns/ breakdowns and also take-up preventive
maintenances and modifications etc. Provisioning cells procure and distribute the spare
parts and consumables to various rigs arid functional units.
II) Operation & Maintenance of equipment in Production Installations/ Platforms:
There are several type of electrical equipment available on a production
installation or platform. These equipment can be broadly divided as follows
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1. Diesel Generator sets/ Gas Turbines: Depending upon the availability of gas
and other factors, Diesel generator sets (D.G. sets) or Gas Turbines (G.T.) are
used as the primary source of power at offshore platforms and a source of standby
power in onshore installations. On onshore installations power is generally taken
from the state electricity boards. All these, equipment are equipped with some
good quality control and protection systems.
2. Transformers: In onshore production installations power is usually received
from state electricity boards at various voltage levels ranging from 11 KV to 220
KV. These high voltages are stepped down to utility voltages using transformers
installed at sub stations. These transformers can be of a few hundred KVA to a
few MVA capacity. Transformers are also used in offshore platforms for stepping
down the voltages. Onshore installations will also have heater treater transformers
used to feed high voltage to electrostatic controls of treaters for separation of
water particles from oil.
3. Substations: Substation comprises of various HT & LT switchgears, controls and
protection units. The high voltage power supply, received from state electricity
board or generated by Gas Turbines is stepped down to distribution level for
distributing to various loads. The switchgears used for HT supply, mainly consists
of MOCBs, SF 6 breakers, OCBs, VCBs etc and that for low voltage panels
consists of switchgears like ACB, switch fuse units, MCCBs, MCBs, ELCBs etc.
Substations also have UPS supply schemes for uninterrupted power supply and
DC power system for protection / controls.
4. Motors and controls: Motors are used as prime mover to Oil dispatch pumps,
effluent dispatch pumps, transfer pumps, gas compressors, air compressors,
loading and unloading pumps. SRP artificial lift pumps, etc. The motors could be
HT motors or LT motors.
HT motors are used for gas compressors/ air compressors; oil dispatch and
effluent dispatch pump motors. These motors range from a few hundred KW to a few
MW and the voltage rating could be from 3.3 KV to 6.6 KV. The motors are mostly 3phase induction motors and specially designed to work in hazardous areas. HT
motors are controlled by Direct online switching using VCBs, SF6 breakers etc or by
autotransformer control through vacuum contactors.
LT motors are also used for the above-mentioned functions. These motors are
usually rated for 415V and could be of capacity of a few KW to about 400 KW. The
controllers used range from DOL .starters, star delta starter, soft starters, variable
speed controllers etc.
5. Base support, provisioning etc.: Providing base support for the men &
equipment at site is also a very important function. These include Field
maintenance parties (FMP) and procurement cells. The FMP attends various
emergency shutdowns/ breakdowns and also under take preventive maintenances
and modifications. Provisioning cells procure and distribute the spare parts and
consumables to various installations/ platforms and functional units.

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6. Air conditioners and lighting systems: Air conditioners are used to control the
temperatures in control cabins (SCAD A/ instrumentation/ UPS etc) and also of
crew rest rooms. Lights are provided in the work areas and peripheries. The
lighting system is of two types; Flame proof and non-flameproof. Flameproof
lightings are used in places where there is a likelihood of encountering
inflammable gases or oil.
III) Operation & Maintenance of equipment in work over rigs: These are small rigs
used for the maintenance and repair of oil wells. These rigs comprises of
following electrical equipment.
1. Generators & switchgear panels: The rig lightings and utilities primarily
depend on DG sets for power. Switchgear panels are used for supply and
controlling power to various loads.
2. Batteries and Battery chargers, self starters and .welding transformers are
other electrical equipment available in work over rigs.
A maintenance engineer is expected to operate, maintain all these equipment, plan
and replace old and outdated equipment.

Specific Role of MECHANICAL ENGINEER

The specific role of Mechanical Engineers is discussed below in three sections:
At Drilling Rigs
At Work Over Rigs
At Production Installations
 At Drilling Rigs
Operation & Maintenance of equipment in drilling rigs: Drilling rigs are used for the
drilling of exploratory as well as development wells. Drilling rigs are of two types:
1.
Mechanical Rigs
2.
Electrical Rigs
Presently on most of the locations, ONGC is using Electrical rigs. Electrical Rigs are
further subdivided into two types: * DC-DC Rigs: In these rigs power for Draw-works and mud-pumps is generated in
DC itself.
AC-SCR Rigs: Diesel Generators are used in drilling rig. The total power required
by the drilling rig is generated by AC Alternators. This AC power is rectified into DC
power for DC motors (Draw-works & Rotary table (in case of independent Rotary
drive) & mud-pumps), using Silicon Controlled Rectifier (SCR) bridges.

RIG EQUIPMENT & MAINTENANCE

RIG EQUIPMENT

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We shall discuss in brief some important aspects related to effective maintenance and
operation of the rig equipment. For this purpose we shall divide the rig equipment to FOUR
main categories:

1-

Power pack system

Mud Handling system
Tackle system
Air System

POWER PACK SYSTEM

The engine coupled with Alternator is known as power pack system. It supplies electrical
power to various AC/DC motors and lighting of Drilling Rig. Most of the ONGC rigs are
equipped with Caterpillar D-399 engines, while at few of the rigs. Cummins KTAT3 067
engines have been installed.
MAIN SUB-SYSTEMS OF DIESEL ENGINE
FUEL SYSTEM
OIL SYSTEM
COOLING SYSTEM
AIR INTAKE SYSTEM
SAFETY SYSTEM - HYDRA MECHANICAL SHUTOFF
a)
Low Oil pressure shut off switch .
b)
High water temperature shut off
c)
Over speed cut off device
2
MUD HANDLING SYSTEM
2.1
MUD PUMPS
These are reciprocating high pressure pump which supplies mud (mixture of
chemicals) to the well. Modern Mud pumps are triplex and single acting. The
three pistons move in dismountable cylinder liners, suck up the fluid by a suction pipe
then discharge it into a discharge pipe through a discharge valve. Triplex pumps
cannot usually suck up fluid
directly from the mud pits because of volumetric efficiency and cavitations risks due to
high linear piston velocities. As a result, they are boosted, or supercharged, by centrifugal
pump. The mud has following major functions:
i)
It lubricates the drill bit & helps in drilling operation.
ii)
It carries well cutting out of well.
iii)
It provides stability to well bore from caving in.
Normally the rig is equipped with 2 nos. of single acting triplex mud pumps. Most of these
pumps are of BPCL make. Hence we shall discuss the various aspects of these pumps,
which in general are common with other makes.

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SI. Pump
No. Specification

BPCL - PUMPS
A600PT A850PT

i.

ii.

Pump
Size
(in inches)
(Max. piston dia
x stroke)
Standard Piston
Size (in inches)

iii.

Rated input BHP

iv.

Max. Working
Pressure
Discharge (psi)
Suction (psi)

Corresponding Rig

A1100PT

A1400PT

A1700PT

7 x8

7.1/2x9

7.1/2x10

7.1/2x10

7.1/2x12

4-7

5-7.1/2

5-7.1/2

5-7.1/2 .

5-7.1/2

600

6000
275
IR-750

850
1700
1100
1400
(175RPM) (160RPM) (150RPM) (150RPM)

5000
250

E-760
IR-900

5000
250

5000
250

5000
250

E-1400

E-2000

E-3000

2.2 SHALE SHAKER

Drilling fluid (mud) returning from the well bore, is first subjected to the shale shaker,
which discards a high percentage of large drilled solids (cuttings). Removal of the
drilled solids in turn leads to higher penetration rate and enhanced service life of mud
pump expendables.
2.3

DESANDER, DESILTER AND MUD CLEANERS

Well cuttings which fall in between 765-74 microns are removed by Desander,
while the cuttings ranging 74-20 microns are removed by Desilter from the
receiving mud.
2.4

DESGASSER

Weighted drilling fluids are sometimes troubled by being gas-cut. This usually happens
in connection with drilling gas bearing formation or as a result of insufficient hydrostatic
pressure of the mud in a well in which case, formation gas would enter the hole. The gas
accompanied with the drilling mud must be vented a safe distance away from the well,
and the liquid mud should be returned to the mud pits in order to prevent waste. In
order to extract complete entrained gases from the mud, it may be necessary to run the
mud into the degasser.
2.5

MUD MIXING UNIT (HOPPER)

'

Normally the rig! is having 2 Jet Hoppers. In actual operation, the mixing pump
(centrifugal type) circulates the fluid mud from the suction tank. The high fluid velocity
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through the jet nozzles lowers the static pressure in the housing to below atmospheric
pressure i.e. a vacuum is created and thus the material placed in the hopper (just
above the nozzle exit) is sucked into the stream of fluid where it gets mixed with the
fluid.
3. TACKLE SYSTEM
3.1

Draw Works - are used for hoisting & lowering the drilling string into the well
bore. This is the most critical equipment from the mechanical point of view. Any fault
in this will directly affect the drilling operations. As there is no standby of this
equipment, the Rig Engineer should focus high attention on its upkeep &
maintenance. The draw works drum is powered by one or more DC motors.
Various drum speeds are obtained by engaging; the different clutches in the draw
works. As the draw works reel in the block line onto the drum, the travelling block
moves up. The draw works drum is also controlled by a braking system, to lower the
traveling1 block. The brake is released and the weight of the travelling block move the
block down ward.

Specifications of the various models of BHEL Draw Works have been tabulated
below :

PARAMETERS
Horsepower
Rating
Drilling
depth
Range with 41/2"
OD
drill
pipe

MODELS
E3000

E2000

E1400

E760

3000

2000

1400

1000

9000 mts.

4900 to
6100 mts.

3050 to
4900 mts.

2100 to
3650 mts.

EDDY CURRENT BRAKE

BHEL Draw Works are equipped with Eddy Current Brakes. This brake utilizes the
principle of eddy currents used to produce retarding torque to retard the accelerating
speed of the string during running in operation.
3.2
SWIVEL.
The swivel serves the following purpose
i)
It supports the rotating equipment and
ii) Provides a fluid channel from non-rotating circulating system to the rotating
equipment.
Brief description of swivels equipped with BHEL rigs is indicated as under:

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PARAMETERS
Max.
Recommended
RPM
Dead load capacity, API

PC650

PC425

PC300

400

400

400

650 tons

425 tons

300 tons

3.3 TRAVELLING BLOCK & CROWN BLOCK

The crown block sits on the top of the mast. The drilling line is reaved over the crown
and traveling block sheaves so four or more lines are between the crown and traveling
block. One end of the drilling line is connected to the drum of draw works. The other end of
the drilling line, the dead line, is securely clamped to the substructure. The remaining part
of drilling line is coiled on a storage spool. Drilling'load such as drill pipe and casing
are, connected to a bracket on the bottom of the traveling block.
Brief description of various models of Traveling Blocks equipped with BHEL Rigs is
given as under:
Specification Models
s
Rig
(E3000)
Load Capacity
750 Tons
No. of Sheaves
Out Side Dia
of. Sheaves
Wireline Size

3.4

(E2000)
650 Tons

(El 400)

(E760)

500 Tons

350 Tons

(1525 mm).

(1524 mm)

(1524 mm)

(1524 mm)

1.3/8 inches

1.1/4 inches

1.1/4 inches

1.1/4 inches

ROTARY TABLE

The rotary table is a large metal table fitted with a ring gear and seated on heavy-duty
roller bearings. The ring gear is driven by a pinion gear connected to a rotary drive
sprocket. The sprocket is connected to a sprocket in the draw works by a rotary chain.
Brief description of various models of Rotary Table equipped with BHEL Rigs is given as
under:-

Parameters

Models
B 37
(E3000)

Rated Supportable 650 tons

Max.Table Speed 350 rpm
Max.Table opening 37 inches

A 27
(E760/J400/E200
0)
500 tons
500 rpm
27 inches

A 20
(IR750/2OOO)
(IR400/3000)
350 tons
500 rpm
20 inches

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4. AIR SYSTEM
Compressed air is extensively used on the drilling rigs for actuating clutches and various
rig controls. Air is also used to start power packs, to run BOP accumulator pumps, to
drive Kelly spinner; to actuate power tongs, power slips and to control catheads.
Independently driven compressors are housed in an utility house. One diesel
driven air compressor and two electric motor driven compressors (normally
termed, as elect. Compressor) are sufficient to fulfil requirement of the rig.
Mechanical compressor is normally used to supply the air for cranking of power
pack engines. Thereafter when electrical power is generated, electrical
compressors are normally used.
4.1
MECHANICAL COMPRESSOR
Most commonly used mechanical compressor with the drilling rigs has the following
specifications : Free air delivery
Piston Displacement
Maximum Working pressure
Power rating of diesel engine
4.2
ELECTRICAL COMPRESSORS
= 40 CFM
= 40 CFM
= 175 PSI
= 12.5 BHP at 1500 RPM
These compressors are generally equipped with the rig along with automatic pressure
switch, which makes the compressor on .'Auto' start as soon as the pressure falls
below 7 kg/cm2. It stops at 10 kg/cm2.
4.2.1. RECIPROCATING TYPE ELECTRICAL COMPRESSORS
In the most of the electrical rigs supplied till mid-eighties, reciprocating electrical
compressors were supplied with the rigs. These compressors were mostly two
stages with inter cooling between the stages.
4.2.2. SCREW TYPE ELECTRICAL COMPRESSSORS
Drilling rigs supplied after mid-eighties; have been equipped with screw type electrical
compressors. There are two moving parts in the casing of screw compressor- the
rotors. The male rotor lobes, function as piston, that roll in the female rotor flutes - function as an cylinder. The male rotor does the compression, the female rotor is an
idler.
5.
CONCLUSION
To conclude, drilling operation and rig maintenance go hand in hand. The job of the tool
pusher is facilitated by the maintenance engineer. Lack of attention to the maintenance
affects the equipment availability, which ultimately results in the below par performance
of the rig. Therefore to keep the rig performance at the highest level, maintenance has to
be accorded its due performance, if not more.

Role At Production Installations

The Production installations have different streams of operations and the equipment
are designed to meet specific requirements of each stream. These are:
Oil Production, processing and despatch
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 Gas Production, processing and despatch.

.
Utility equipment which include
*
Power Generation
*
Water Management
* Waste Management
* Materials Handling
* Boat/Helicopter Handling
* Living Quarter equipment
* Refrigeration & Air conditioning.
*
Safety equipment
Major equipment associated with each of above are explained below.
I) Oil Production, Processing and Despatch
At Offshore installations

Main Oil Line (MOL) Pumps /Crude Transfer Pumps (CTP)

At offshore production installations, there are Multi-Stage Centrifugal Pumps driven by
Turbines or Heavy duty motors. The objective of MOL pumps is to pump the semi
processed crude oil in the main trunk line at Mumbai High for transportation to onshore
processing terminal at Uran ,the pressure required to be maintained is around 90
kg/cm2.The MOL pumps are installed at BHN, BHS,ICP, SHP & NPC platform. These
pumps push around 3.24 lacs Barrels a day of crude Oil to Uran Oil Processing
Complex. The CTPs act as feedstock pumps which transfer Crude from platforms to
MOL.
As no leakages are allowed at Oil/Gas installations the Seals designed for these pumps
need special mention. The Mechanical seals, used in CTP's are Tungsten Carbide type.
Discharge flow range - 120 - 700 ml/hr, discharge press. Range - 91.5 - 116.5 kg/cm2.
Onshore installations
The reciprocating Sucker Rod Pumps (SRP) are installed at many locations where the oil
does not flow by natural pressure. These are special type of reciprocating pumps which
are installed at surface of the well and the fluid end of pump installed deep inside the well
is connected by connecting rod. Special screw pumps are also installed at some of the
wells.
For purpose of treating crude oil a variety of additives (notably PPD-pour point
depressant) are added to it by number of dosage pumps. These small, low volume
reciprocating pumps can be calibrated to pump in exact quantity of chemicals in given
time.
2) Gas Production, Processing and Despatch
Process Gas Compressors:
They are Multi stage Centrifugal compressors which are used to increase/boost the
pressure of the associated gas in oil fields or the natural gas of producing fields from
around 4-5 kg/cm2 to an output of around 90-100 kg/cm2 and thus push the gas in
offshore sub-sea pipelines to reach gas processing complexes at Uran & Hazira. The
compressors are directly coupled to turbines through' a gear box. The gas compressors
which are multistage centrifugal type and dispatch the compressed gas to onshore
terminals at Uran or Hazira Gas compressors of makes like Kawasaki, IHI, MAN-GHH.
Dresser Rand are installed at offshore platforms.
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The sealing of the gas compressors is achieved by using LABYRINTH Oil Seal .Further
the balancing of the compressor is carried out by dynamic monitoring. Orbital vibration
monitoring equipment arc installed for this purpose on the compressor itself.
Capacity Range - 1 . 2 1 - 2 . 5 MMSCMD, Discharge Press Range - 53 to 125 kg/sq.cm
Rated speed Range (7533 - 11120 rpm)
The Booster .Compressors installed at some installations are powered by Electrical
Motors. The quality of Oil seal oil/Lubricating Oil is maintained by rigidly carrying out
Chemical analysis of the oil in local laboratory.
3) Utilities
a) Power Generation
Gas Turbine generators
Like at oil Rigs, the production installations have their own captive power generation.
The capacity rating of Gas Turbines installed for the purpose varies from 0:8 to 15.2 MW.
These turbines have a captive consumption of the gas (which is properly treated in Gas
Treating Skid before being fed into the turbine).
In ONGC we have around 122 Gas Turbines (including the turbines installed for power
generation or coupled to Gas Compressors) of various makes with a total installed
capacity of over 950 MW , which is around 50% of Base load of Delhi State.
Basically two types of gas turbines are available in offshore, namely aero derivative and
industrial type. Gas turbines of various makes like Rolls Royce, GE, Alstom, Solar, ManGHH, Nupvo Pignone are installed. These turbines are used either for power generation
or as mechanical drives for gas compressors. These machines are one of the most
critical equipment installed on production platforms for operations.
Gas turbines are also installed at Hazira Plant, Uran Plant, CPF Gandhar & CPP in ER
for power generation.
A gas turbine consists of largely TWO parts namely Gas Generator & Power Turbine.
Gas Generator is a consolidated unit of a multistage inlet air Compressor and a two stage
turbine. Maintenance teams are fully responsible for the maintenance and repair of these
critical equipment. The state of art DGS-Digital control Systems, Vibration Monitoring
Systems are important tools in this task. Holistic maintenance of the accessories (Lub Oil
system, Seal Oil System, intake air system, Gas Conditioning Skid, Exhaust cooling
systems) is equally important in upkeep of these turbines.
Utility/Emergency Diesel Generators
These diesel generators are installed for black start up of the production installations in
case of power or emergency shutdown of the platform, due to various reasons. These
generators supply power to gas turbine auxiliary motors, instrument air compressors and
lighting panels of the platforms.
b) Water Management
Sea water lift pumps ( SWLP)
These pumps are submersible type multistage centrifugal pumps used to lift the sea water
from sea for cooling the well stream natural gas before further processing it on the
production platform. These pumps are driven by vertical type electric motors.
Discharge flow range - 800 m3 /hr - 2040 m3 / hr, Discharge press range - 6.6- 12.0
kg/cm2.
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Main Injection Pumps (MIP)

These pumps are used for water injection to maintain the reservoir pressure of oil fields.
These pumps are multi-stage centrifugal pumps driven by electric motors.
Discharge flow range - 397 to 835 m3 /hr, Discharge press. Range -132-144 kg /cm2
Potable water makers
The watermakers are installed on offshore production platforms to produce potable water
from sea water for drinking purposes and to make up the potable water used in
processing of hydrocarbons. Two types of water makers are available. Reverse Osmosis
type and Vapour Compression (VC) type.
c) Waste Management
Sump cassion pumps are installed to recirculate the crude oil from sump cassion to the oil
surge tank.
Sewage treatment/ effluent treatment plants are installed to chemically and physically
treat the sewage from the living quarters and the waste from galley/ kitchen before being
discharged into the sea to meet the statutory environmental regulations for offshore
installations.
d) Materials Handling
Various material handling equipment like pedestal cranes, overhead cranes, overhead
electric & pneumatic winches are installed to transfer the material from one place to
another on the platform or from' offshore supply boats to platform and vice-versa. The
overhead cranes and winches are also used to carry out maintenance jobs on various
equipment.
e) Galley equipment
Various galley equipment like deep freezer, vegetable freezer, dough maker, ice cream
machine, tea & coffee making machines, electric ovens for cooking etc. are installed at
offshore platforms
f) Heating, ventilation & Air conditioning equipment
For efficient functioning of control systems installed for various equipment in process
control rooms and turbine generator control rooms and for safety reasons to avoid
ingress of inflammable hydrocarbons in case of emergency all these areas are kept
pressurized and a temperature of around 25 degree centigrade is maintained through
heating, ventilation and air conditioning ( HVAC ) equipment like air handling units,
chillers handling units and pressurizing units. In addition, all the living quarter areas
like residential rooms, recreation rooms, galleys, offices etc. are also temperature,
humidity and pressure controlled.
g) Safety equipment
Fire water pumps which are submersible centrifugal type pumps are installed to supply
sea water in case of fire on the platform. These pumps are kept in AUTO START mode
to supply sea water to fire water header in case of fire. Fire water hoses, sprinkler
systems etc. are available to extinguish fire in open areas and living quarters.
Halon gas fire extinguishing systems are available to suppress any fire in enclosed areas
like gas turbine enclosures, control rooms, offices etc.
Fire & gas detection panels are installed in control rooms to automatically detect fire and
leakage of gas in all the areas and initiate visual and audible alarms to alert all the
personnel of any emergency situation.

408

h) Instrument/Utility air compressors

These compressors are multi-stage reciprocating type and supply compressed air to
various pneumatic instruments/panels to control the processing of crude oil/natural gas.
The compressed air is passed through air driers to absorb any moisture to ensure proper
functioning of pneumatic instruments/panels Pressure drop in the instrument air, header
below the prescribed limit will cause shut down of the process platform.
Utility air is used to run the pneumatic winches & other pneumatic tools and in surge
tanks of service water system.
Discharge Pressure range : 7-10 kg/ cm2, discharge flow range: 500- 750 m3/ hr
D. Role of Mechanical Engineers in maintenance management of offshore
equipment
1. To carry out planning for scheduled overhaul and maintenance of all the
equipment installed on the production platform particularly the critical equipment
like TG, PGC, MOL, etc. This planning includes forecasting of spares
requirement and provisioning of the some well in advance keeping in mind the
lead time required for procurement activity.
2.

to carry out the scheduled overhaul & preventive maintenance of all the
equipment as per the guidelines/procedures recommended by the OEM.

3. To carry out the predictive maintenance

i.e. Condition monitoring of the
equipment through various techniques like vibration analysis, baroscopic
inspection, lubricant analysis etc. to avoid unscheduled down time caused by
breakdown or premature failure of the components.
4. To undertake the unscheduled breakdown repair jobs and make the equipment
operational as early as possible.
5.

To ensure the general upkeep of the equipment through regular cleaning and
painting. To ensure safe operating conditions by ensuring proper safety guards on
belt drives, coupling covers, etc.

409